U.S. patent application number 14/633798 was filed with the patent office on 2016-09-01 for web of cleaning products and method of manufacture.
The applicant listed for this patent is MONOSOL, LLC. Invention is credited to David Brian Edwards.
Application Number | 20160251131 14/633798 |
Document ID | / |
Family ID | 55543065 |
Filed Date | 2016-09-01 |
United States Patent
Application |
20160251131 |
Kind Code |
A1 |
Edwards; David Brian |
September 1, 2016 |
WEB OF CLEANING PRODUCTS AND METHOD OF MANUFACTURE
Abstract
A web of cleaning products and a method of manufacturing the
same is disclosed. The web includes a carrier sheet having a
plurality of depressions each filled, and in direct contact with,
at least one cleaning composition. A plurality of internal lids
that correspond with the plurality of depressions are sealed to the
carrier sheet in a manner covering the plurality of depressions.
Additionally, a plurality of external lids that correspond with the
plurality of internal lids are sealed to the carrier sheet and
cover the plurality of internal lids. The carrier sheet and
external lids may be made of a water-resistant material, and the
internal lids may be made of a water-soluble material. In one
embodiment, the internal lids may be omitted, and instead the
depressions be filled with water-soluble pouches, each of which
contains a respective dose of a cleaning composition.
Inventors: |
Edwards; David Brian; (Old
Town Stevenage, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MONOSOL, LLC |
Merrillville |
IN |
US |
|
|
Family ID: |
55543065 |
Appl. No.: |
14/633798 |
Filed: |
February 27, 2015 |
Current U.S.
Class: |
206/524.7 |
Current CPC
Class: |
B65D 65/466 20130101;
B65D 77/06 20130101; B65B 7/02 20130101; B65D 2213/00 20130101;
B65D 2251/0031 20130101; B65D 43/02 20130101; B65D 2543/00833
20130101; B65D 2577/205 20130101; B65B 61/182 20130101; B65B 3/04
20130101; B65D 2251/009 20130101; C11D 17/049 20130101; B65D 75/40
20130101; B65D 51/185 20130101; B65D 2575/3227 20130101; B65D 51/18
20130101; B65D 77/2024 20130101; B65D 65/46 20130101; B65D
2251/0093 20130101; B65D 75/44 20130101; B65D 2215/00 20130101;
B65D 2251/0018 20130101; B65B 61/005 20130101; B65D 75/327
20130101; B65D 2251/0028 20130101 |
International
Class: |
B65D 65/46 20060101
B65D065/46; B65B 7/02 20060101 B65B007/02; B65D 51/18 20060101
B65D051/18; B65B 61/18 20060101 B65B061/18; B65D 43/02 20060101
B65D043/02; B65B 3/04 20060101 B65B003/04; B65B 61/00 20060101
B65B061/00 |
Claims
1. A web of cleaning products comprising: a carrier sheet having a
plurality of depressions, each filled and in direct contact with at
least one cleaning composition; a plurality of internal lids
corresponding with the plurality of depressions and being sealed to
the carrier sheet to cover the plurality of depressions; and a
plurality of external lids corresponding with the plurality of
internal lids and being sealed to the carrier sheet to cover the
plurality of internal lids.
2. The web of claim 1, each of the plurality of external lids
including an outer peripheral edge defined by a weakened tear line
allowing a user to individually remove the plurality of external
lids from the web one at a time.
3. The web of claim 2, each of the plurality of external lids
including a pull tab that projects outwardly of an outer peripheral
edge of the carrier sheet and facilitates removal of the associated
external lid.
4. The web of claim 1, the carrier sheet having a circular outer
peripheral edge and each of the plurality of depressions being
pie-shaped.
5. The web of claim 4, the circular outer peripheral edge of the
carrier sheet having a mean outer diameter in a range of
approximately 10-35 cm and approximately 20-26 cm.
6. The web of claim 4, each of the plurality of depressions being
divided into two or more cavities each filled with a different
cleaning composition.
7. The web of claim 1, the carrier sheet and the external lids
being made of a water-resistant material.
8. The web of claim 7, the internal lids being made of a
water-soluble material.
9. The web of claim 1, each of the plurality of external lids being
separately sealed to the carrier sheet such that removal of one of
the external lids does not compromise the seal of the remaining
external lids.
10. The web of claim 1, each external lid covering a larger surface
area of the carrier sheet than its corresponding internal lid.
11. The web of claim 1, the carrier sheet being made of a rigid
material.
12. A web of cleaning products comprising: a water-resistant
carrier sheet having a plurality of pie-shaped depressions; a
plurality of water-soluble pouches each positioned in a
corresponding one of the plurality of pie-shaped depressions and
containing at least one cleaning composition; and a plurality of
water-resistant external lids sealed to the carrier sheet and
covering the plurality of pie-shaped depressions.
13. The web of claim 12, the water-resistant carrier sheet having a
circular outer peripheral edge.
14. The web of claim 13, the circular outer peripheral edge of the
water-resistant carrier sheet having a mean outer diameter in a
range of approximately 10-35 cm and approximately 20-26 cm.
15. The web of claim 12, each of the plurality of water-resistant
external lids including an outer peripheral edge defined by a
weakened tear line allowing a user to individually remove the
plurality of water-resistant external lids from the web one at a
time.
16. The web of claim 15, each of the plurality of water-resistant
external lids including a pull tab that projects outwardly of an
outer peripheral edge of the water-resistant carrier sheet and
facilitates removal of the associated water-resistant external
lid.
17. The web of claim 12, each of the plurality of pie-shaped
depressions containing two or more water-soluble pouches.
18. The web of claim 12, the at least one cleaning composition
being at least one of a dishwashing detergent, a water softener, or
a rinse aid.
19. The web of claim 12, each of the plurality of water-resistant
external lids being separately sealed to the water-resistant
carrier sheet such that removal of one of the external lids does
not compromise the seal of the remaining external lids.
20. The web of claim 12, the water-resistant carrier sheet being
made of a rigid material.
21. A method of making a web of cleaning products, the method
comprising: forming a plurality of depressions in an upper surface
of a first carrier sheet; filling each of the plurality of
depressions with at least one cleaning composition; positioning a
film to cover the first carrier sheet and sealing the film to the
upper surface of the first carrier sheet about a rim of each of the
plurality of depressions; cutting the film to define a plurality of
internal lids, each of the plurality of internal lids covering a
corresponding one of the plurality of depressions; removing an area
of waste material produced by cutting the film to expose portions
of the upper surface of the first carrier sheet; positioning a
second carrier sheet to cover the first carrier sheet and sealing
the second carrier sheet to the exposed portions of the upper
surface of the first carrier sheet; and forming a plurality of
weakened tear lines in the second carrier sheet to define a
plurality of external lids, each of the plurality of external lids
covering a corresponding one of the plurality of internal lids.
22. The method of claim 21, each of the plurality of external lids
including a pull tab that projects outwardly of an outer peripheral
edge of the first carrier sheet and allows a user to individually
remove the plurality of external lids from the web.
23. The method of claim 21, comprising cutting the first carrier
sheet to possess a circular outer peripheral edge and forming each
of the plurality of depressions with a pie-shaped
cross-section.
24. The method of claim 23, forming each of the plurality of
weakened tear lines along respective radial lines extending from a
center of the circular shape of the first carrier sheet.
25. The method of claim 21, comprising forming each of the
plurality of depressions with two or more cavities, and filling the
two or more cavities with different cleaning compositions.
26. The method of claim 21, the first and second carrier sheets
being made of a water-resistant material.
27. The method of claim 26, the film being made of a water-soluble
material.
Description
TECHNICAL FIELD
[0001] The present disclosure generally relates to packaging and,
more particularly, to packaging for unit and multi-dose cleaning
products.
BACKGROUND
[0002] Unit dose cleaning products are commonly used in dishwashing
and other cleaning applications. A unit dose cleaning product
typically comprises a water-soluble pouch filled with a cleaning
composition (e.g., a powdered detergent, a liquid rinse aid, a
water softener, etc.). Water used in a cleaning cycle, such as an
automatic dishwasher cleaning cycle, dissolves the water-soluble
pouch and releases the cleaning composition. The amount of cleaning
composition inside each water-soluble pouch typically corresponds
to the amount needed for a single cleaning cycle. Therefore, a user
is not required to measure an appropriate amount of the cleaning
composition for the cleaning cycle. This increases convenience to
the user and makes accidental spills less likely. Also, enclosing
the cleaning composition inside the water-soluble pouch reduces the
risk of skin contact with the cleaning composition.
[0003] The exterior walls of the water-soluble pouch are typically
very thin and thus susceptible to damage, particularly during
transport and storage. If the water-soluble pouch is exposed to
water, water vapor, oxygen, or any other potentially corrosive
element prior to use, the water-soluble pouch may prematurely
dissolve and release its contents. Furthermore, shifting and
contact with other items during transport may inadvertently
puncture the skin of the water-soluble pouch.
[0004] To protect the water-soluble pouches from damage prior to
use, the water-soluble pouches are typically packaged within a
laminated barrier bag. However, if one of the water-soluble pouches
breaks inside the laminated barrier bag due to, for example,
mechanical shock, the leaked contents of the damaged water-soluble
pouch may compromise the other water-soluble pouches inside the
laminated barrier bag. Also, the laminated barrier bag typically
must have a re-sealing mechanism so that the consumer can re-seal
the laminated barrier bag after removing one of the water-soluble
pouches for use. Such re-sealing mechanisms increase the
manufacturing costs and time associated with the laminated barrier
bag. Also, laminated barrier bags tend to be bulky and difficult to
stack, and thus oftentimes require a substantial amount of shelf
space. Still further, a consumer must store the laminated barrier
bag in a cabinet between uses, and must un-seal and re-seal the
laminated barrier bag each time a water-soluble pouch is to be
retrieved. This can be inconvenient and time-consuming for the
user.
[0005] Furthermore, laminated barrier bags are typically made from
materials (e.g., oriented polypropylene (OPP), biaxially oriented
polypropylene (BOPP), polyethylene (PE), etc.) that fall under
Classification #7 of the Standard Classification System for
Specifying Plastic Materials. Such materials are generally
difficult to recycle, making them undesirable from an environmental
perspective.
SUMMARY
[0006] One aspect of the present disclosure provides a web of
cleaning products including a carrier sheet and a plurality of
internal and external lids. The carrier sheet may have a plurality
of depressions each filled, and in direct contact with, at least
one cleaning composition. The plurality of internal lids may
correspond with the plurality of depressions and may be sealed to
the carrier sheet to cover the plurality of depressions. The
plurality of external lids may correspond with the plurality of
internal lids and may be sealed to the carrier sheet to cover the
plurality of internal lids.
[0007] Another aspect of the present disclosure provides a web of
cleaning products including a water-resistant carrier sheet, a
plurality of water-soluble pouches, and a plurality of
water-resistant external lids. The water-resistant carrier sheet
may have a plurality of pie-shaped depressions. The plurality of
water-soluble pouches may each be positioned in a corresponding one
of the plurality of pie-shaped depressions and contain at least one
cleaning composition. The plurality of water-resistant external
lids may be sealed to the carrier sheet and cover the plurality of
pie-shaped depressions.
[0008] Yet another aspect of the present disclosure includes a
method of making a web of cleaning products. The method includes:
(a) forming a plurality of depressions in an upper surface of a
first carrier sheet; (b) filling each of the plurality of
depressions with at least one cleaning composition; (c) positioning
a film to cover the first carrier sheet and sealing the film to the
upper surface of the first carrier sheet about a rim of each of the
plurality of depressions; (d) cutting the film to define a
plurality of internal lids, each of the plurality of internal lids
covering a corresponding one of the plurality of depressions; (e)
removing an area of waste material produced by cutting the film to
expose portions of the upper surface of the first carrier sheet;
(f) positioning a second carrier sheet to cover the first carrier
sheet and sealing the second carrier sheet to the exposed portions
of the upper surface of the first carrier sheet; and (g) forming a
plurality of weakened tear lines in the second carrier sheet to
define a plurality of external lids, each of the plurality of
external lids covering a corresponding one of the plurality of
internal lids.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective assembly view of one embodiment of a
web of cleaning products constructed in accordance with principles
of the present disclosure.
[0010] FIG. 2 is a perspective view of the web of cleaning products
of FIG. 1 without the external and internal lids and without the
cleaning compositions.
[0011] FIG. 3 is a top view of the web of cleaning products of FIG.
1 without its external lids.
[0012] FIG. 4 is a bottom view of web of cleaning products of FIG.
1.
[0013] FIG. 5 is a schematic representation of one embodiment of a
method of making a web of cleaning products in accordance with
principles of the present disclosure.
[0014] FIG. 6 is a schematic representation of cutting away excess
portions of a film to create individual internal lids.
[0015] FIG. 7 is a perspective view of another embodiment of a web
of cleaning products constructed in accordance with principles of
the present disclosure.
[0016] FIG. 8 is a perspective view of another embodiment of a web
of cleaning products constructed in accordance with principles of
the present disclosure.
DETAILED DESCRIPTION
[0017] The present disclosure generally concerns the manufacture of
a web of cleaning products that can endure multiple cleaning cycles
and which is configured to release multiple doses of a cleaning
composition one at time over the course of several cleaning cycles.
This configuration allows a user to leave the web inside a cleaning
environment, such as an automatic dishwasher, throughout multiple
cleaning cycles, without premature release of its internal
contents. Only the cleaning product(s) opened by the user prior to
the cleaning cycle have their contents released during the cleaning
cycle. The remaining cleaning products are protected inside the web
until they are opened. Accordingly, the presently disclosed web
frees the user from having to store the web in a dry environment
such as a cabinet between cleaning cycles. Conveniently, the user
can store the web inside the cleaning environment, indefinitely, if
so desired, without concern that the unused cleaning products will
be released prematurely. In one embodiment, the web may be sized
and dimensioned similar to a dish plate so that the web can be held
by a dish rack, or other dish holder, of an automatic dishwasher.
Accordingly, the dishwasher may not require modification to
accommodate the web of cleaning products.
[0018] FIG. 1 illustrates one possible embodiment of a web 8 of
cleaning products 10. The web 8 includes a carrier sheet 20 having
a generally circular shape and a plurality of depressions 24 formed
in its upper surface 26. As depicted in FIG. 2, the depressions 24
may be arrayed across the carrier sheet 20 in a pattern resembling
slices of a pie. As a result, each depression 24 defines a
respective sector of the circular shape of the carrier sheet 20,
with the lateral sides of each depression 24 extending along
respective imaginary radial lines emanating from the center of the
carrier sheet 20. Other arrangements of the depressions 24 are
envisioned, including a pattern of parallel and aligned rows and
columns of the depressions 24. Also, as an alternative to the
pie-shaped cross-section, the depressions may have a cross-section
that is circular, square, rectangular, polygonal, or any other
suitable shape.
[0019] The outer diameter D of the carrier sheet 20 may be
substantially similar to that of a dinner plate. Preferably, the
outer diameter D is between approximately (e.g., .+-.10%) 10-35 cm
or, more preferably, 15-30 cm or, most preferably, 20-26 cm. By
dimensioning and shaping the carrier sheet 20 similar to a dinner
plate, the carrier sheet 20 can more easily fit into a dish rack,
or other dish holder, within an automatic dishwasher.
[0020] The carrier sheet 20 is preferably made of a water-resistant
material (e.g., a water-insoluble, hydrophobic material such as
plastic) and is preferably rigid. The rigidity of the carrier sheet
20 may enable the web 8 to be oriented in an upright configuration
in a dish rack of a dishwasher without sagging under its own
weight. The carrier sheet 20 may be capable of withstanding
multiple cleaning cycles within an automatic dishwasher with little
or no degradation. Preferably, the carrier sheet 20 is made of a
material having a melting point above 100.degree. C., and, more
preferably, above 150.degree. C., so that the carrier sheet 20 does
not thermally deform during the heated drying cycle of an automatic
dishwasher. Suitable materials for the carrier sheet 20 include,
but are not limited to, polyester and nylon/polyethylene laminates,
preferably in their amorphous form. The carrier sheet 20 may be
made of a recyclable material (e.g., polyethylene terephthalate
(APET), polypropylene, etc.) so that the environmental impact of
disposing the carrier sheet 20 is reduced. The carrier sheet 20 may
be made of a recyclable material (e.g., polyethylene terephthalate
(APET), polypropylene, etc.) so that the environmental impact of
disposing the carrier sheet 20 is reduced. In some embodiments, the
carrier sheet 20 may be made of a carbon neutral, or substantially
carbon neutral, material such as for example, a biopolymer or
another material derived from a biomass source (e.g., sugar beets,
potatoes, wheat, etc.). One example of a suitable carbon neutral
material for the carrier sheet 20 is BIOFRONT.RTM. manufactured and
sold by Teijin Limited. BIOFRONT.RTM. is a type of biopolymer
produced from a plant-based feedstock, and in some embodiments, may
have a stereocomplex crystalline structure. The thickness of the
carrier sheet 20 may be within a range between approximately (e.g.,
.+-.10%) 60-1000 .mu.m, or 170-750 .mu.m, or lesser or greater. In
one embodiment, the carrier sheet 20 is a water-resistant film that
is 170 .mu.m thick and made from amorphous polyester APET. The
carrier sheet 20 may be thermoformed to create the depressions 24,
as discussed below in more detail.
[0021] Each of the depressions 24 defines an internal cavity 28
that is filled with a cleaning composition 30. The cleaning
composition 30 may be in direct contact with the walls of the
depression 24 as illustrated in FIG. 1. While the depressions 24
illustrated in FIG. 1 each have a single cavity 28 filled with a
single cleaning composition 30, other embodiments can be arranged
differently, with each depression 24 being divided into multiple
cavities by one or more internal walls, and with each cavity being
filled with a different cleaning composition. An embodiment
configured in this manner is discussed below in connection with
FIG. 7.
[0022] The cleaning composition 30 may be any composition which is
intended to be released in an aqueous environment. The cleaning
composition 30 may be a dishwashing detergent, a laundry detergent,
a water softener, a rinse aid, salt enzyme, bleach, a bleach
activator, a surface cleaner, etc. The cleaning composition 30 may
have disinfectant, antibacterial, or antiseptic properties. The
cleaning composition 30 may take any appropriate form including,
but not limited to, a liquid, a gel, a paste, a solid, granules, or
a powder. In one embodiment, the cleaning composition 30 may take
the form of a mull, consisting of a mixture of particles which are
insoluble in a carrier (e.g., a mixture containing water-soluble
particles and a glycerol or propylene glycol carrier incapable of
dissolving the water-soluble particles).
[0023] Referring to FIG. 3, each of the depressions 24 may be
covered with one of a plurality of internal lids 40. The internal
lids 40 hold each dose of the cleaning composition 30 in its
respective depression 24 prior to use. Each of the internal lids 40
may be sealed to the upper surface 26 of the carrier sheet 20 about
the rim of a corresponding depression 24. A line of sealing
material 42 may surround the rim of each of the depressions 24 to
facilitate adhesion between the internal lids 40 and the upper
surface 26 of the carrier sheet 20. As an alternative, or as an
addition, to the lines of sealing material 42, the internal lids 40
may be welded (e.g., heat welded, vibration welded, ultrasonic
welded, radio frequency welded, solvent welded, or any combination
thereof) to the carrier sheet 20. In one embodiment, the internal
lids 40 may be radio frequency welded to the carrier sheet 20 with
the use of radio frequency welding equipment and/or production
methods made available by Stanelco PLC.
[0024] The shape of the internal lids 40 may correspond to that of
the depressions 24. As depicted in FIGS. 1 and 3, each of the
internal lids 40 may be pie-shaped like its corresponding
depressions 24, and each may have lateral sides extending along
respective imaginary radial lines emanating from the center of the
carrier sheet 20. The area covered by each internal lid 40 may be
larger than the footprint of its corresponding depression 24 such
that the internal lid 40 covers and seals close the depression
24.
[0025] The internal lids 40 are preferably made of a water-soluble
material (e.g., a hydrophilic material), may be flexible or rigid.
The internal lids 40 may be cold-water soluble or hot-water
soluble. A cold-water soluble material is one that is soluble in
water at 20.degree. C. or less, while a hot-water soluble material
is one which is soluble in water at 60.degree. or more. Material
which is soluble between these temperatures can also be used. An
internal lid 40 made of a cold-water soluble material may release
the cleaning composition 30 in three minutes or less when placed in
un-agitated water at 20.degree. C. or less. An internal lid 40 made
of a hot-water soluble material may release the cleaning
composition 30 in three minutes or less when placed in un-agitated
water at 60.degree. or more.
[0026] The internal lids 40 may be made from a mono-layer film or a
multi-layer laminated film that is cut into the individual internal
lids 40. Furthermore, the internal lids 40 may be perfumed or
colored to obtain aesthetically pleasing characteristics, or from
any combination of these features. In some embodiments, the
internal lids 40 may be transparent or translucent. In some
embodiments, different internal lids 40 may be made of different
grades, thicknesses, and/or materials.
[0027] Preferred materials for the internal lids 40 include
polyvinyl alcohol (PVOH), cellulose derivatives such as cellulose
ethers, polyglycolides, polylactides, and/or
polylactide-polyglycolide copolymers. In cold water applications,
hydroxypropyl methyl cellulose (HPMC), as well as any of the
foregoing materials, may be used for the internal lids 40. The PVOH
may be partially or fully hydrolyzed homopolymer of polyvinyl
acetate (e.g., a copolymer of vinyl alcohol groups and vinyl
acetate groups, or all vinyl alcohol groups). Additionally, the
PVOH may be a partially or fully hydrolyzed modified PVOH (for
example 1-10 mole % anionic copolymer comprising groups such as
monomethyl maleate sodium salt or 2-Acrylamido-2-methylpropane
sulfonate sodium salt. For example, the PVOH may be alcoholised or
hydrolysed in a range between 40-100%, or between 70-92%, or
between 88-92%. The degree of hydrolysis is known to influence the
temperature at which the PVOH starts to dissolve in water. 88%
hydrolysis corresponds to a film soluble in cold (e.g., room
temperature) water, whereas 92% hydrolysis corresponds to a film
soluble in warm water. The material for the internal lids 40 may
also, in various embodiments, contain plasticizers and mold release
agents, which may facilitate the manufacturing of the internal lids
40. The material may be produced by any process including, for
example, extrusion, blowing, and/or casting. The material may be
un-oriented, mono-axially oriented, or bi-axially oriented. If the
layers are oriented, they usually have the same orientation,
although their planes of orientation may differ.
[0028] The thickness of the internal lids 40 may be in a range
between approximately (e.g., .+-.10%) 20-500 .mu.m, or 30-300
.mu.m, or 35-200 .mu.m, or between 40-160 .mu.m, or 40-150 .mu.m,
or 40-120 .mu.m. In one embodiment, the internal lids 40 may be
made of a PVOH film available as MonoSol M8630, and may have a
thickness of approximately (e.g., .+-.10%) 75 .mu.m.
[0029] Referring to FIG. 1, each of the internal lids 40 may be
covered with a corresponding one of a plurality of external lids
50. The external lids 50 protect the internal lids 40 from
potentially corrosive elements such as water, water vapor, oxygen,
etc., as well as mechanical damage, prior to use. Each of the
external lids 50 may be sealed to the upper surface 26 of the
carrier sheet 20 about the outer peripheral edge of a corresponding
internal lid 40. Accordingly, the surface area of the carrier sheet
20 covered by an external lid 50 may be larger than the surface
area of the carrier sheet 20 covered by its corresponding internal
lid 40. FIG. 1 illustrates that a line of sealing material 52 may
surround the outer peripheral edge of the corresponding internal
lid 40 to facilitate adhesion between the external lid 50 and the
upper surface 26 of the carrier sheet 20. The lines of sealing
material 52 may be made of a low tack peelable adhesive (e.g., a
UV-curable acrylic oligomer) allowing the external lid 50 to be
pulled away from the carrier sheet 20 by a user. As an alternative,
or as an addition, to the lines of sealing material 52, the
external lids 50 may be welded (e.g., heat welded, vibration
welded, ultrasonic welded, radio frequency welded, solvent welded,
or any combination thereof) to the carrier sheet 20. In one
embodiment, the external lids 50 may be radio frequency welded to
the carrier sheet 20 with the use of radio frequency welding
equipment and/or production methods made available by Stanelco
PLC.
[0030] The shape of the external lids 50 may correspond to that of
the internal lids 40. As depicted in FIG. 1, the external lids 50
may be planar and pie-shaped like the internal lids 40. The area
covered by each external lid 50 may be larger than the footprint of
its corresponding internal lid 40 such that the external lid 40 can
properly cover and seal close the internal lid 40.
[0031] The external lids 50 are preferably made of a
water-resistant material (e.g., a water-insoluble, hydrophobic
material such as plastic) and are preferably at least semi-rigid.
In one embodiment, the external lids 50 are made of the same
material as the carrier sheet 20. The external lids 50 may be
capable of withstanding multiple cleaning cycles of an automatic
dishwasher with little or no degradation. Preferably, the external
lids 50 are made of a material having a melting point above
100.degree. C., and, more preferably, above 150.degree. C., so that
the external lids 50 do not thermally deform during the heated
drying cycle of an automatic dishwasher. Alternatively, the
external lids 50 may be made of a material having a melting point
below 100.degree. C., for example, any temperature within a range
between approximately (e.g., .+-.10%) 50-100.degree. C. Suitable
materials for the external lids 50 include polyester and
nylon/polyethylene laminates, preferably in their amorphous form.
The thickness of each of the external lids 50 may be within a range
between approximately (e.g., .+-.10%) 60-1000 .mu.m, or 170-750
.mu.m, or lesser or greater. Preferably, the external lids 50 are
made of a recyclable material (e.g., APET, polypropylene, etc.) so
that the environmental impact of disposing the external lids 50 is
reduced. In one embodiment, the external lids 50 are made of a
water-resistant film that is 170 .mu.m thick and made from
amorphous polyester APET.
[0032] The external lids 50 may be made from a single sheet of
material that is divided into sections by weakened tear lines 54,
with each section corresponding to one of the external lids 50.
Each weakened tear line 54 may form an outer peripheral edge of
adjacent external lids 50, as illustrated in FIG. 1. The weakened
tear lines 54 may be formed by any suitable method including, for
example, laser etching and/or scoring. As shown in FIG. 1, each
weakened tear line 54 may each extend along a respective imaginary
radial lines emanating from the center of the carrier sheet 20.
[0033] The weakened tear lines 54 facilitate individual detachment
of the external lids 50 from the web 8. A user can remove one of
the external lids 50 to expose the internal lid 40 underneath
without compromising the seal protecting the other internal lids
40. Following removal of the external lid 50, the exposed internal
lid 40 may be dissolved by water in a cleaning cycle to release the
cleaning composition 30 in the depression 24 underneath.
[0034] To facilitate removal of the external lids 50 from the web
8, each of the external lids 50 may be formed with a pull tab 56
that projects outwardly of the outer peripheral edge of the carrier
sheet 20. FIG. 4 is a bottom view of the web 8 and illustrates the
extension of the tabs 56 beyond the outer peripheral edge of the
carrier sheet 20. A user may grip the pull tab 56 to pull and tear
the external lid 50 from the web 8 and thereby expose one of the
internal lids 40.
[0035] Each of the cleaning products 10 may be defined by the
combination of one of the depressions 24, the cleaning composition
30 filling the depression 24, and the internal and external lids
40, 50 covering the depression 24. In some embodiments, each
external lid 50 may cover two or more depressions 24 such that each
cleaning product 10 is defined by the two or more depressions 24,
two or more cleaning compositions 30, two or more internal lids 40,
and a single external lid 50. In such an embodiment, each cleaning
product 10 may include two or more different cleaning compositions,
and the internal lids 40 of each cleaning product 10 may dissolve
at a different rate. For example, one of the cleaning compositions
within a cleaning product 10 may be dishwashing detergent, and the
other one of cleaning compositions may be a water-softener, salt,
enzyme, rinse aid, bleach, or bleach activator. The internal lid
used for the water-softener, salt, enzyme, rinse aid, bleach, or
bleach activator may dissolve at a faster rate than the internal
lid used for the dishwashing detergent. Accordingly, the
water-softener, salt, enzyme, rinse aid, bleach, or bleach
activator may be released near the start of an automatic dishwasher
cleaning cycle, whereas the dishwashing detergent may be released
near the end of the automatic dishwasher cleaning cycle.
[0036] Various aspects of the web 8 of cleaning products 10 reduce
the likelihood that a child will be able to access and/or want to
ingest the cleaning composition 30. The weakened tear lines 54 may
provide a first line of defense in that a small child may not have
the gripping force to tear away one of the external lids 50 from
the web 8. In some embodiments, the force needed to break the
weakened tear lines 54 may be equal to or greater than
approximately (e.g., .+-.10%) 250 N, or equal to or greater than
approximately (e.g., .+-.10%) 300 N. Additionally, since the
cleaning compositions 30 are hidden from view by the carrier sheet
20 and the external lids 50, colors and/or scents associated with
the cleaning compositions 30 are less likely to tempt the child to
open the web 8 in order to gain access to the cleaning compositions
30.
[0037] Secondary measures may also be implemented to ensure that,
even if the child is able to remove one or more of the external
lids 50, the child is prevented and/or deterred from bursting the
internal lids 40 and/or ingesting the cleaning compositions 30.
Such measures includes constructing the internal lids 40 to comply
with some or all of the provisions set forth in the COMMISSION
REGULATION (EU) No. 1297/2014 of 5 Dec. 2014 amended, for the
purposes of its adaptation to technical and scientific progress,
Regulation (EC) No. 1272/2008 of the European Parliament and of the
Council on Classification. These provisions concern the safety of
soluble packaging for detergents that are sold in dosages for
single use by consumers. Among these provisions are requirements
that the soluble packaging retain its contents for at least 30
seconds when the soluble packaging is placed in water at 20.degree.
C. Accordingly, in some embodiments, the film 80 used to construct
the internal lids 40 may have the ability to retain the cleaning
compositions 30 within their respective depressions 24 for at least
30 seconds when the internal lids 40 are exposed to water at
20.degree. C. This characteristic of the internal lids 40 may
reduce the risk the internal lids 40 will dissolve if momentarily
placed in the mouth of a child. In addition, the internal lids 40
may be constructed with a bursting strength that is equal to or
greater than approximately (e.g., .+-.10%) 250 N, or equal to or
greater than approximately (e.g., .+-.10%) 300 N. This may prevent
a child from bursting the internal lids 40 with his or her hands
and/or teeth.
[0038] As a tertiary measure, the cleaning compositions 30 may
include an orally-averse agent (e.g., a bittering agent) that
deters a child from swallowing the cleaning compositions 30 in the
event that the child is able to open the internal lids 40. An
example of such an orally-averse agent is denatonium, which is
commonly sold under the trade name Bitrex. Additionally, or
alternatively, the orally-averse agent may be incorporated into the
carrier sheet 20, the internal lids 40, and/or the external lids
50. The orally-averse agent may provide a last line of defense in
the event that the foregoing childproof measures are not effective
in preventing the child from gaining access to the cleaning
compositions 30.
[0039] Additional childproof measures may be incorporated into the
web 8 of cleaning products 10 and the foregoing discussion is not
intended to limit the number or type of childproof measures
suitable for use in the web 8 of cleaning products 10.
[0040] Referring to FIGS. 5 and 6, a method of manufacturing the
web 8 of cleaning products 10 will now be described. FIG. 5
illustrates the carrier sheet 20 being fed from a roll into a
thermoformer 100 where the depressions 24 are created in a
thermoforming process. The thermoforming process may entail vacuum
forming or pressure forming, or some combination of the two. Vacuum
forming may involve heating the carrier sheet 20, pressing a mold
against the carrier sheet 20, and vacuuming out air between the
carrier sheet 20 and the mold so that the carrier sheet 20 assumes
the shape of the mold. Pressure forming may involve heating the
carrier sheet 20, pressing the carrier sheet 20 against a mold by
vacuuming out air between the carrier sheet 20 and the mold, and
applying positive air pressure above the carrier sheet 20 so that
the carrier sheet 20 assumes the shape of the mold.
[0041] After the depressions 24 are formed, they are filled with
the cleaning composition 30 by a filling machine 110. Each of the
depressions 24 may be filled entirely or partially with the
cleaning composition 30. Next, the lines of sealing material 42 may
be applied to the upper surface 26 of the carrier sheet 20 at the
sealing station 120. The lines of sealing material 42 may surround
the rims of each of the depressions 24. The lines of sealing
material 42 may be made of any suitable adhesive material
including, for example, epoxies, polyurethanes, acrylics, and/or
silicones.
[0042] Next, a film 80 for making the internal lids 40 is fed from
a roll into face-to-face contact with the upper surface 26 of the
carrier sheet 20, and pressed against the carrier sheet 20 at the
pressing station 130. The film 80 adheres to the upper surface 26
of the carrier sheet 20 by virtue of the lines of sealing material
42. The adhesion of the film 80 to the carrier sheet 20 creates a
seal around each of the depressions 24 to enclose the respective
doses of cleaning composition 30.
[0043] Next, to convert the film 80 into individual internal lids
40, the film 80 is cut at the cutting station 140. This may be
achieved by die-cutting through the film 80 around the rims of the
depressions 24, but not through the underlying carrier sheet 20.
Subsequently, the waste in-between material may be removed at a
rewind station 150. FIG. 6 illustrates a plan view of this
operation. After cutting the film 80 at the cutting station 140,
the waste material 85 is removed upwards to the rewind station 150,
leaving behind the separated internal lids 40 covering their
respective depressions 24. Portions of the upper surface 26 of the
carrier sheet 20 are exposed by this process. The cutting and
removal process may be similar to that used in the flat bed
die-cutting of self-adhesive labels (in which only the
self-adhesive face material is cut, leaving the self-adhesive label
adhering to the uncut siliconed release material).
[0044] Once the internal lids 40 have been cut and the waste
material 90 removed, the lines of sealing material 52 may be
applied to the exposed portions of the upper surface of the carrier
sheet 20 at the sealing station 160. Each of the internal lids 40
may be surrounded by a line of sealing material 52. Suitable
materials for the lines of sealing material 52 may be made of any
suitable adhesive material including, for example, epoxies,
polyurethanes, acrylics, and/or silicones. In one embodiment, the
lines of sealing material 52 may be made of a low tack peelable
adhesive (e.g., a UV-curable acrylic oligomer), which allows the
external lids 50 to be pulled away from the carrier sheet 20 by a
user.
[0045] Next, a carrier sheet 90 is fed from a roll into
face-to-face contact with the upper surface 26 of the carrier sheet
20 and the internal lids 40, and pressed against the carrier sheet
20 at the pressing station 170. The carrier sheet 90 adheres to the
upper surface 26 of the carrier sheet 20 by virtue of the lines of
sealing material 52. The adhesion of the carrier sheet 90 to the
carrier sheet 20 results in a seal around each of the internal lids
40.
[0046] Subsequently, the weakened tear lines 54 may be formed in
the carrier sheet 90 at the cutting station 180. The weakened tear
lines 54 may divide the carrier sheet 90 into the external lids 50.
The weakened tear lines 54 may be formed by any suitable method
including, for example, laser etching and/or scoring. As
illustrated in FIG. 1, the weakened tear lines 54 may be formed
along respective radial lines each extending from a center of the
carrier sheet 20.
[0047] As final step, the carrier sheet 20 and the overlapping
carrier sheet 90 may be cut into a circular shape, or any other
suitable shape, at the cutting station 190, thereby creating the
web 8 of cleaning products 10. In one embodiment, the cutting
operation may produce a web having a hexagonal, heptagonal, or
octagonal outer peripheral edge, or any other substantially
circular shape.
[0048] The web 8 of cleaning products 10 can be implemented in a
variety of different cleaning applications including an automatic
dishwasher. In such implementations, a user may place the web 8 in
a rack, or other holder, inside the dishwasher that is typically
used to hold a dish plate. As such, the web 8 may be arranged
alongside and/or between the dish plates during the cleaning cycle.
Prior to the start of the cleaning cycle, a user may grip one of
the tabs 56 and tear a corresponding one of the external lids 50
along the weakened tear lines 54. As a result, the internal lid 40
underneath is exposed. Dirty dishes may then be loaded into the
dishwasher, and the cleaning cycle may be initiated. Water used by
the dishwasher in the cleaning cycle dissolves the internal lid 40,
thereby releasing the cleaning composition 30 of the depression 24
covered by the internal lid 40. The cleaning compositions 30 of the
other depressions 24 remain sealed and protected within the web by
virtue of the un-detached external lids 50 and the carrier sheet
20. When the cleaning cycle is completed, the user may remove the
cleaned dishes, while leaving the web 8 inside the dishwasher.
Accordingly, the user does not have to store the web 8 in a cabinet
between uses. Later, when another load of dirty dishes requires
cleaning, the user may repeat the foregoing process by removing
another one of the external lids 50 of the web 8.
[0049] Referring to FIG. 7, a second embodiment of the web 208 of
cleaning products 210 will now be described. The foregoing
description of the first embodiment of the web 8 is applicable to
similar elements of the second embodiment of the web 208. Similar
elements of the second embodiment have the same reference numeral
as their first embodiment counterpart, with the addition of the
digit "2" as a prefix.
[0050] The primary difference between the first and second
embodiments is that each depression 224 of the second embodiment
has multiple internal cavities 292a, 292b, each of which contains a
different cleaning composition 294a, 294b. The internal cavities
292a, 292b are divided by an internal dividing wall 295 that
extends between opposite perimeter walls of the depression 224. The
different cleaning compositions 292a, 292b may perform functions
that complement each other during a cleaning cycle. For example,
the cleaning composition 292a may be a dishwashing detergent,
whereas the cleaning composition 292b may be a water-softener,
salt, enzyme, rinse aid, or bleach activator. An additional line of
sealing material 296 may be applied across the upper surface of the
internal dividing wall 295. The line of sealing material 296
adheres to the internal lid 240 to keep the cleaning compositions
292a, 292b in their respective cavities 292a, 292b prior to
dissipation of the internal lid 240. While each depression 224 of
the second embodiment is divided into two cavities, in other
embodiments, each depression may be divided into three or more
cavities, each containing a different cleaning composition.
[0051] Turning to FIG. 8, a third embodiment of a web 308 of
cleaning products 310 will now be described. The foregoing
description of the first embodiment of the web 8 is applicable to
similar elements of the third embodiment of the web 308. Similar
elements of the third embodiment have the same reference numeral as
their first embodiment counterpart, with the addition of the digit
"3" as a prefix.
[0052] The primary difference between the first and third
embodiments is that each depression 324 of the third embodiment
contains a pouch 391 filled with a cleaning composition 330. The
cleaning composition 330 therefore does not directly contact the
walls of the depression 324. Also, the third embodiment of the web
308 does not include a plurality of internal lids sealed to the
carrier sheet 320 about a rim of each of the depressions 324.
[0053] Each pouch 391 may be formed by an internal holder 392 and
an internal lid 393. The internal holder 392 may have a cavity 394
that holds the cleaning composition 330. The internal lid 393 may
be sealed to the rim of the open end of the internal holder 392. As
illustrated in FIG. 8, each pouch may be pie-shaped and correspond
to the shape of its depression 324.
[0054] The internal holders 393 may be created by thermoforming a
first film together with the carrier sheet 320 at the same time, in
the manner as described in U.S. Patent Publication No.
2004/0142131, which is hereby incorporated by reference in its
entirety. This process creates a temporary, or permanent, affinity
between the first film and the carrier sheet 320 that reduces the
effects of shrink-back, as discussed in U.S. Patent Publication No.
2004/0142131. Accordingly, it may be possible to fill the entire
volume of each of the internal holders 393 will the cleaning
composition 330. Once filled, internal holders 393 may be sealed
shut by sealing a second film to the rims of the internal holders
393. Subsequently, the individual pouches 391 may be separated from
each other by die-cutting through the second film, but not through
the underlying carrier sheet 320, and then removing the waste
in-between material resulting from the cutting operation. The
cutting process may be similar to the one described U.S. Patent
Publication No. 2004/0142131.
[0055] The first and second films may each be made from the same
material as the internal lid 40 described above. Accordingly, the
pouches 391 formed by the first and second films may be
water-soluble. The carrier sheet 320 may be water-resistant and
made from the same material(s) as the carrier sheet 20 described
above.
[0056] The third embodiment of the web 308 may be used in the same
manner as the first embodiment of the web 8, for example, by being
stored inside a dishwasher over the course of multiple cleaning
cycles. Also, since each does of the cleaning composition is
enclosed within one of the pouches 391, the web 308 can be stored
in a cabinet, and the user can retrieve a pouch 391 for use in a
cleaning cycle without having to remove the web 308 from the
cabinet. Accordingly, the third embodiment of the web 308 provides
additional flexibility in how it is used by the consumer.
[0057] From the foregoing, it can be seen that the disclosed
embodiments advantageously provide improved configurations and
methods of forming a web of cleaning products. The ability to leave
the leave the web of cleaning products within a cleaning
environment during multiple cleaning cycles eliminates the need to
store the cleaning products in a dry environment prior to their
use. Instead, the user can simply place the web of cleaning
products within the cleaning environment, and store it there, if so
desired, until all of its cleaning products have been released.
Also, since the web of cleaning products can be dimensioned and
shaped like a dish plate, the web of cleaning products can be held
by a dish rack, or other dish holder, of a conventional automatic
dishwasher. Accordingly, dishwashers should not require
modification to accommodate the web of cleaning products of the
present disclosure. Still further, the web of cleaning products can
be configured such that each cleaning product contains two or more
different cleaning compositions, releasable at time different times
during a cleaning cycle, which can improve cleaning efficiency.
Also, since the protective, water-resistant portions of the web can
be made of a recyclable material, the environmental impact of
disposing the web, after dispersal of the cleaning compositions, is
reduced.
[0058] While the present disclosure has been described with respect
to certain embodiments, it will be understood that variations may
be made thereto that are still within the scope of the appended
claims.
* * * * *